How Are Wood Pellets Made: Understanding The Manufacturing Process

BBQ wood pellets have revolutionized the world of outdoor cooking and grilling, providing a convenient and eco-friendly fuel source for your grill, smoker, or stove. But how are wood pellets made, these small, cylindrical pieces of wood, and what factors influence the quality and flavor of the final product?

It Starts With Premium Barrel Staves

What’s a stave, you ask? They’re the individual side “slats” that make a wooden barrel.

Fifty years ago, our company began operation in the southeast corner of Minnesota, just outside Caledonia. We are a preferred maker of barrel staves used by some of the most well-known brands of wine and whiskey in the world. Our customers include fine wineries from France, Italy, Australia, and California. We’re also proud to provide staves that add their flavor influences to the distinctive tastes of two popular brands of whiskey – Jack Daniel’s® and Woodford Reserve®. We are recognized as a leading producer of world-class staves for the premium wine and whiskey industries, shipping to their cooperages (barrel makers) around the globe.

Sourcing Raw Materials – How Are Wood Pellets Made

How are wood pellets made: The first step in making BBQ wood pellets is sourcing the raw materials. These materials typically include sawdust, shavings, and other waste products generated by the lumber industry. In some cases, manufacturers may also use wood chips or other forms of wood waste. The key is to use materials that are free of contaminants, such as dirt, bark, or resin, which can affect the flavor and quality of the final product.

how are wood pellets made, white oak log stacked

Using Oak and What Makes Stoaked BBQ Pellets So Special

There’s a great deal of science and research that goes into the process of making premium wines and whiskeys. An essential step is finding the right wood for the aging process, which takes place within the barrels. White oak is the wood of choice. And, not all white oak meets the high standards necessary to achieve desired results.

Stoaked has the good fortune of being situated in the midst of some of the most sought-after white oak on earth. Our geographic latitude is similar to that of the Bordeaux region of France, meaning our white oak shares a similar nature with French species of white oak that have been used for centuries to produce the distinctive wine flavor complexities found nowhere else.

Whiskey producers also found our particular white oak desirable for its superior structure and flavor-infusing characteristics. Our local white oaks take their time growing. The slow growth results in a fine grain that keeps out air while infusing rich layers of flavorings into the barrel contents.

And, STOAKED BBQ wood pellets will perform very well in your pellet grill or smoker. By nature, white oak burns with more BTUs than most other pellet woods, so the same-size purchase goes further. Since our food-grade pellet composition is pure and consistent, you can expect the same experience every time – with virtually no ash to clean up afterward.

All of our white oak is carefully selected for quality and consistency. Stoaked’s ongoing sustained forest growth stewardship ensures that our locally-sourced resources will be maintained and abundant.

The Drying Process

Once the raw materials have been sourced, they must be dried to a specific moisture content. This is an important step in the manufacturing process, as too much moisture can result in a lower-quality product that is difficult to burn. The drying process can be done in a variety of ways, including kiln drying, air drying, or vacuum drying.

how are wood pellets made chipping process


The next step in how are wood pellets made during the manufacturing process is pelletizing, which is the process of compressing the dried wood waste into small, cylindrical pellets. This is done using a pellet mill machine, which uses high pressure and heat to compress the wood waste into a dense, uniform shape.

The quality and uniformity of the pellets produced by the pellet mill are influenced by several factors, including the type of wood used, the moisture content of the raw materials, and the temperature and pressure used during the pelletizing process.

Flavor Infusions

Some manufacturers may choose to add flavor infusions to their wood pellets to create unique and delicious flavors. This can be done by adding natural ingredients, such as herbs, spices, or fruit extracts, to the raw materials before the pelletizing process. The flavor infusion will then be incorporated into the finished product, providing a unique and delicious flavor that will impress your guests.

Packaging and Shipping

The final step in the manufacturing process of wood pellets is packaging and shipping. The finished BBQ wood pellets are typically packaged in bags and then shipped to retailers or consumers. The packaging process must be done carefully to ensure that the pellets remain in good condition during transport and storage.

How Are Wood Pellets Made: Understanding the Manufacturing Process

BBQ wood pellets are a convenient and eco-friendly fuel source for your grill, smoker, or stove. The manufacturing process for these pellets is a complex and detailed process, involving several key steps, including sourcing raw materials, drying, pelletizing, flavor infusions, and packaging and shipping. Understanding the process and the factors that influence the quality and flavor of the final product is essential for anyone who wants to get the most out of their cooking or grilling experience.

Scroll to Top